Mitsubishi 2033D SERIES User manual

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2033D SERIES
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MITSUBISHI ELECTRIC 2033D SERIES UPS
MITSUBISHI ELECTRIC AUTOMATION, INC.
UNINTERRUPTIBLE POWER SUPPLY SYSTEM
2033D SERIES
OWNERS / TECHNICAL MANUAL
Revision 1.3: December 18, 2003
ALN-H0963
23D_00s.doc MITSUBISHI ELECTRIC 2033D SERIES UPS
MITSUBISHI
ELECTRIC
2033D SERIES UPS
OWNERS / TECHNICAL MANUAL
Page Number:
i
Preface
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ii
TABLE OF CONTENTS
LIST OF TABLES ............................................................................................... iii
LIST OF FIGURES ............................................................................................ iv
HOW TO USE THIS MANUAL ........................................................................... v
1.0 INTRODUCTION ....................................................................................... 1-1
1.1 GENERAL ................................................................................................. 1-3
1.2 DEFINITIONS ............................................................................................ 1-4
1.3 OVERVIEW ............................................................................................... 1-5
1.4 SPECIFICATIONS .................................................................................... 1-11
2.0 OPERATOR CONTROLS AND INDICATORS ......................................... 2-1
2.1 LED DISPLAY ........................................................................................... 2-2
2.2 MBP LAMP....................................................................................................2-2
2.3 EPO BUTTON ........................................................................................... 2-2
2.4 LIQUID CRYSTAL DISPLAY ..................................................................... 2-3
2.5 EXTERNAL SIGNAL TERMINAL BLOCK ................................................. 2-8
2.6 EXTERNAL COMMUNCATION CONNECTOR .......................................... 2-13
3.0 INSTALLATION AND OPERATION ......................................................... 3-1
3.1 TRANSPORTATION AND INSTALLATION .............................................. 3-1
3.2 INSTALLATION PROCEDURE ................................................................. 3-1
3.3 PROCEDURE FOR CABLE CONNECTIONS ........................................... 3-3
3.4 OPERATING PROCEDURES ................................................................... 3-12
3.5 MAINTENANCE BYPASS SET-UP PROCEDURES ....................................3-13
4.0 RESPONSE TO UPS FAILURE ................................................................ 4-1
5.0 PARTS REPLACEMENT .......................................................................... 5-1
6.0 FAULT CODES ......................................................................................... 6-1
7.0 WARRANTY & OUT OF WARRANTY SERVICE ..................................... 7-1
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iii
List of Tables
Table 1.1 Power Specifications ................................................................... 1-11
Table 1.2 UPS Module Information.............................................................. 1-11
Table 1.3 Detail of Specifications ................................................................ 1-12
Table 1.4 Rating of Contactor and Fuses .................................................... 1-13
Table 3.1 How to Transport and Install the System..................................... 3-1
Table 3.2 List of UPS Weights (lb.).............................................................. 3-1
Table 3.3 Type and number of Battery ........................................................ 3-2
Table 3.4 Maximum Permitted Fault Current............................................... 3-3
Table 3.5 Recommended Cable Size and Torque Requirements ............... 3-5
Table 3.6 Crimp Type Compression Lug ..................................................... 3-6
Table 6.1 Fault Code ................................................................................... 6-2
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List of Figures
Figure 1.1 Single Line Diagram-Normal Operation .................................................... 1-5
Figure 1.2 Single Line Diagram-Bypass Operation.................................................... 1-6
Figure 1.3 Single Line Diagram-Battery Operation .................................................... 1-7
Figure 1.4 UPS Parts Location .................................................................................. 1-8
Figure 1.5 UPS Parts Location (Continued)............................................................... 1-9
Figure 1.6 External I/F circuit PCB IOAU-05.............................................................. 1-9
Figure 2.1 Operation/Display Panel ........................................................................... 2-1
Figure 2.2 Main Screen ............................................................................................. 2-3
Figure 2.3 Start/Stop Screen ..................................................................................... 2-4
Figure 2.4 PIN Protection Screen .............................................................................. 2-4
Figure 2.5 Bypass Voltage Abnormal Message Screen............................................. 2-4
Figure 2.6 Measurement Screen ............................................................................... 2-4
Figure 2.7 Setup Screen............................................................................................ 2-5
Figure 2.8 Log Select Screen .................................................................................... 2-5
Figure 2.9 Event Log Screen ..................................................................................... 2-5
Figure 2.10 Battery Log Screen ................................................................................. 2-6
Figure 2.11 Main Screen (Battery Operation) ............................................................ 2-6
Figure 2.12 Measurement Screen (Battery Operation) ................................................ 2-6
Figure 2.13 Main Screen (Fault Indication) ................................................................ 2-7
Figure 2.14 Message Screen ..................................................................................... 2-7
Figure 2.15 External Signal Terminal Block................................................................. 2-8
Figure 2.16 Control Wiring for External Contacts ........................................................ 2-10
Figure 2.17 Remote "Start" Contact Connections........................................................ 2-11
Figure 2.18 External communication connector........................................................... 2-13
Figure 3.1 UPS Terminal Designation ...................................................................... 3-7
Figure 3.2 Diagram of input/output bus bars and terminal blocks ............................ 3-8
Figure 3.3 Diagram of Power Wire Connect (Parallel Connection) .......................... 3-10
Figure 3.4 Diagram of Power Wire & Control Wire Connect (Parallel Connection ) . 3-11
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v
How to use this Manual
This manual is designed for ease of use, giving the user easy and quick reference to
information.
This manual uses notice icons to draw attention to the user important information regarding the
safe operation and installation of the UPS. The notice icons used in this manual are explained
below, and should be taken into account and adhered to whenever they appear in the text of
this manual.
Warning: A warning notice icon conveys information provided to protect
the user and service personnel against hazards and/or possible equipment
damage.
Caution: A caution notice icon conveys information provided to protect
the user and service personnel against possible equipment damage.
Note: A Note notice icon indicates when the user should make a reference of
information regarding the UPS operation, load status and display status.
Such information is essential if Mitsubishi field service group assistance and
correspondence is required.
Safety Recommendations: If any problems are encountered while following this manual,
Mitsubishi field service group assistance and correspondence is recommended.
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Page Number:
1-1
1.0 INTRODUCTION
Your Mitsubishi Uninterruptible Power Supply System (UPS) is designed to provide many
years of reliable protection from power failure, brown-outs, line noise, and voltage transients.
To ensure optimum performance of the equipment, follow the manufacturer's instructions. This
manual contains descriptions required to operate the UPS. Please read this manual carefully
and retain it for future reference.
This manual contains important instructions for the 2033D Series Uninterruptible Power Supply
System that should be followed during installation and maintenance of the UPS and batteries.
Lethal voltages exist within the equipment during operation. Observe all
warning and cautions in this manual. Failure to comply may result in
serious injury or death. Obtain qualified service for this equipment as
instructed.
IMPORTANT SAFETY INSTRUCTIONS
RETAIN THESE INSTRUCTIONS
WARNING 1
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This UPS does not include a Bypass input circuit breaker (MCCB) to protect bypass
circuit. Bypass input circuit breaker (MCCB) are to be field supplied and installed.
Recommended Breaker (MCCB)'s Specifications are as follows:
Capacity (kVA) Bypass Voltage (Vac) Bypass Rating (Aac)
Recommended
Breaker (Aac)
30 480 36 45
50 480 60 80
80 480 96 125
AC input and AC output over current protection and disconnect devices shall be field
supplied and installed. DC output over current protection and disconnect device shall
be field supplied and installed. The over current protection device shall be rated as
indicated in TABLE 1.4.
WARNING 2
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1.1 GENERAL
The Mitsubishi 2033D Series UPS is designed to provide continuous and clean electrical
power to a critical load. Additionally the UPS monitors power conditions affecting the load.
In the event of an input power failure, the UPS will supply power to the critical load for the
specified battery time.
If the input power is not restored promptly, back up power from the UPS battery permits
the orderly shutdown of equipment supported by the UPS. The UPS is simple to start-up,
operate and maintain.
The 2033D Series UPS is available in three (3) kVA sizes-30, 50 and 80kVA, and also in
two (2) output voltages - 208V and 480V. Specifications for each kVA and voltage model
appear in Section 1.4. 30kVA model have batteries included in the UPS module cabinet.
50 and 80kVA models have external batteries. The principles of operation described herein
are applicable to all models.
This manual provides an overview of the 2033D Series components and their functions.
The appearance and purpose of operator controls and indicators is described with
procedures for operation, start-up, shutdown and basic maintenance included.
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1.2 Definitions
UNINTERRUPTIBLE POWER SUPPLY SYSTEM (UPS) - All components within the UPS
Module Cabinet and associated batteries that function as a system to provide continuous,
conditioned AC power to a load. This is sometimes referred to as the "System".
UPS MODULE CABINET - The metal enclosure which contains the Converter, the Inverter,
the Chopper, the Static Transfer Switch, the Internal Bypass line, the operator controls,
and the internal control system required to provide specified AC power to a load.
UPS MODULE - The Converter and Inverter assemblies which, under the direction of the
internal control system and operator controls, provide specified AC power to a load.
CONVERTER/BOOSTER - The UPS components which contain the equipment and
controls necessary to convert input AC power to regulated DC power required for battery
charging and for supplying power to the Inverter.
INVERTER - The UPS components which contain the equipment and controls necessary
to convert DC power from the Converter, or the battery, to AC power required by the
critical load.
CHOPPER - The UPS components which contain the equipment and controls necessary
to charge the battery and supply power to the Inverter from battery.
STATIC TRANSFER SWITCH - The device which connects the critical load to the bypass
line when the UPS module cannot supply continuous power.
BYPASS LINE - The line which conducts electricity directly from the input power source to the
critical load during Maintenance or whenever the UPS is not completely operational.
INPUT POWER - Power provided by the electrical utility company, or auxiliary generator,
which is connected to the UPS for supplying the critical load.
BATTERY - The rechargeable battery strings which supply DC power to the inverter to
maintain continuous AC power to the load during AC input power failure conditions
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1.3 Overview
The UPS provides two power paths between the utility source and the critical load.
Figure 1.1 shows the path for normal operation, with the load powered from the inverter.
Figure 1.2 shows the path for bypass operation, with the load supplied through the static
bypass line.
Figure 1.3 shows the path for battery operation, with the load supplied from the inverter.
A) Normal Operation.
FIGURE 1.1 Single Line Diagram - Normal Operation. Load powered by inverter
During normal operation, the path through the inverter is used to power the load.
Referring to Figure 1.1: Input AC power is converted to DC by the Converter. DC power is
utilized to charge the UPS battery and to provide power to the Inverter. The Inverter
converts the DC power to clean AC power to supply the critical load.
The conversion - inversion process eliminates any voltage transients or fluctuations
existing in the input power before it reaches the critical load.
* The AC Bypass Input circuit breaker (MCCB) for protection of the UPS and cables are field
supplied and field installed. (See WARNING 2 on page 1-2)
UPS Module
Power Flow
Not in Use
AC input
CB
FB
72B
52RS
CONVERTER
INVERTER
Output
52C
52RC
FI
FO
BATTERY
User
su
pp
lied
52CS
Maintenance
Bypass
Switch
50kVA, 80kVA:
External Battery
Static Transfer
Switch
CB
AC Bypass
In
put
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B) Internal Static Bypass Line
FIGURE 1.2 Single Line Diagram- Bypass Operation. Load fed through static bypass line.
Referring to Figure 1.2, the Internal Static Bypass line is a Hard wired line through Static
Transfer Switch which supplies the critical load with unconditioned input power. The
purpose of this line is to route power to the critical load while the UPS module is
de-energized during Start-up before the system is fully operational.
The internal control system determines the operation of the two paths, with the load
powered from the inverter being the normal operation.
UPS Module
Power Flow
Not in Use
CB
FB
72B
52RS
CONVERTER
INVERTER
Output
52C
52RC
FI
FO
BATTERY
User
su
pp
lied
52CS
Maintenance
Bypass
Switch
50kVA, 80kVA:
External Battery
Static Transfer
Switch
CB
AC Bypass
In
put
AC input
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C) Inverter supply at battery operation
FIGURE 1.3 Single Line Diagram - Battery Operation
Referring to Figure 1.3: In the event of AC input source failure or interruption, the
converter will de-energize and the battery will immediately discharge and supply DC
power to the inverter to maintain continuous AC power to the load. This operation will
continue until:
a) The battery capacity expires and the inverter turns off, or
b) Input power is restored after which the converter will power the inverter and critical
load and simultaneously recharge the batteries.
A fully charged battery will provide power for the specified time at the rated load, or longer,
at a reduced load.
When power is restored after a low battery shutdown, the converter automatically restarts
operation, recharges the batteries and the Inverter is automatically restarted without
operator intervention. Load is automatically assumed by the inverter without operator
intervention.
The power drawn by the load is equally shared between all system UPS during battery
operation.
UPS Module
Power Flow
Not in Use
AC input
CB
FB
72B
52RS
CONVERTER
INVERTER
Output
52C
52RC
FI
FO
BATTERY
User
su
pp
lied
52CS
Maintenance
Bypass
Switch
50kVA, 80kVA:
External Battery
Static Transfer
Switch
CB
AC Bypass
In
put
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FIGURE 1.4-a UPS Parts Location (30kVA)
FIGURE 1.4-b UPS Parts Location (50kVA, 80kVA)
2. Grounding Bar
52C
UPS module
FRONT VIEW
Inverter
unit
72B
52CS
1. External I/F
Circuit PCB
IOAU-05
Converter Unit
52RC
Chopper Unit
52RS
GND GND ELEC
TERM
DC
Capacitor
Parallel
I/F PCB
2. Grounding Bar
52RS
UPS module
FRONT VIEW
Inverter
unit
52RC
52CS
1. External I/F
Circuit PCB
IOAU-05
Converter
Chopper Unit
72B
52C
GND
GND ELEC TERM
Parallel
I/F PCB
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FIGURE 1.5 UPS Parts Location (Continued)
FIGURE 1.6 External I/F PCB IOAU-05
UPS module
BACKSIDE OF FRONT DOOR(Right side)
|
FAULT
RESET
|
MAINTENANCE
BUTTON
|
TEST
SWITCH
|
BOOT
SWITCH
SYNC.LED
INVERTER
START
|
INVERTER
STOP
|
8
7
9
10
5
6
IOAU-05
3. External Contact Signal Terminal
4. RS232C D-sub Connector
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Description of Figures 1.4, 1.5, and 1.6:
1. External I/F Board (IOAU-05) : FOR SERVICE PERSONNEL ONLY (FIGURE 1.6):
- (3) External contact signal terminal
- (4) RS232C communication connector
2. Grounding Bar (E)
3. External Contact Signal Terminal Block - Terminal block to connect contact signal
input/output lines to and from the external devices. Refer to Figure 2.15 section 2.5 for
details.
4. RS232C Communication Connector - Refer to Figure 2.18 section 2.6 for details.
5. “INVERTER” START Switch - This switch is used to transfer the UPS from static bypass
to inverter during maintenance purposes. Transfers will lock-out if the bypass voltage is
more than +10%,-10% of nominal.
* Uninterrupted switching is made at the time of synchronous operation. Switching is impossible at
the time of asynchronous operation.
6. “INVERTER STOP” Switch - This switch is used to transfer the UPS from inverter to static
bypass during maintenance purposes. Do not operate it under normal operation. Transfers
will lock-out if the bypass voltage is more than +10%,-10% of nominal.
* Uninterrupted switching is made at the time of synchronous operation. Switching is impossible at
the time of asynchronous operation.
7. “FAULT RESET” Switch (FOR SERVICE PERSONNEL ONLY) - This switch resets
errors resulting from alarm conditions. (Do not operate this switch while inverter and
converter are in operation.)
8. Maintenance (Set) Button (FOR SERVICE PERSONNEL ONLY) - This switch sets the
UPS menu parameters.
9. “Test mode” Switch (FOR SERVICE PERSONNEL ONLY) - This switch changes system
operation to the test-mode. (This switch should not be operated by personnel other than
an Authorized Service Engineer).
10. “BOOT” Switch (FOR SERVICE PERSONNEL ONLY) - This switch boots the processor
in the main control circuit resulting from alarm conditions. (Do not operate this switch
while inverter and converter are in operation).
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1.4 Specifications
The UPS name plate displays the rated kVA as well as nominal voltages and currents. The
name plate is located on the inside of the UPS front door.
TABLE 1.1 Power Specifications
Rated output
Power
Input voltage
3 phase / 3 wire
Bypass input voltage
3 phase / 3 wire
Output voltage
3 phase / 3 or 4 wire
30kVA / 24kW
50kVA / 40kW
80kVA / 64kW
480V
480V
480V
480V
480V
480V
208V or 480V
208V or 480V
208V or 480V
TABLE 1.2 UPS Module Information
UPS
[kVA]
CABLE
ENTRY
WIDTH
[in / mm]
DEPTH
[in / mm]
HEIGHT
[in / mm]
WEIGHT
[lb./ kg]
HEATING
[kBTU/h]
30 BOTTOM 33.9 / 860 31.5 / 800 70.9 / 1800 2060 / 930 9.1
50 BOTTOM 33.9 / 860 31.5 / 800 70.9 / 1800 1810 / 820 13.5
80 BOTTOM 33.9 / 860 31.5 / 800 70.9 / 1800 1990 / 900 21.6
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TABLE 1.3 Detail of Specifications
Rated Output kVA 30 50 80
Rated Output kW 24 40 64
AC INPUT
Configuration 3 phase, 3 wire
Voltage 480 V +15% to -15% (-30% can be operated)
Frequency 60 Hz (45.4Hz to 65Hz)
Reflected Current THD 4% typ. at 100% load; 7% typ. at 50% load
STATIC BYPASS INPUT
Configuration 3 phase, 3 wire
Voltage 480 V +/-10%
Frequency 60 Hz
BATTERY
Type Lead Acid
Ride Through Application Specific
Nominal Voltage 480 Vdc
Minimum Voltage 401 Vdc
Number of Cells 240
AC OUTPUT
Configuration 3 phase, 4 wire
Voltage 120/208 V, 277/480 V
Voltage Stability +/-1%
Frequency 60 Hz
Frequency Stability +/-0.05% in free running mode
Power Factor 0.8 nominal
Power Factor range 0.8 - 1.0 lagging (within output kW rating)
Voltage THD 2% typical THD at 100% Linear Load
5% typical THD at 100% non-linear load
Transient Response +/-3% at 100% load step
+/-1% at loss/return of AC power
+/-3% at load transfer to/from static bypass
Transient Recovery 16.6ms
Inverter Overload 125% for 10 minutes, 150% for 1 minute
System Overload 1000% for 1 cycle (with bypass available)
Bypass Overload 150% for 1 minutes
ENVIRONMENTAL
Cooling Forced Air
Operating Temperature
32ﾟF ~ 104ﾟF (0ﾟC - 40ﾟC)
Recommended 68ﾟF - 86ﾟF (20ﾟC - 30ﾟC)
Relative Humidity 5% ~ 95% Non Condensing
Altitude 0 ~ 9000 feet No Derating
Location Indoor (free from corrosive gases and dust)
(PCB conformally coated for use in industrial environment)
Paint Color Munsell 5Y7/1 (Beige)
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TABLE 1.4 Rating of Contactors and Fuses
OUTPUT CAPACITY OF EQUIPMENT
2033D-B 2033D-A 2033D-B
30VA 50kVA 50kVA 80kVA
NUMBER APPLICATION
208V 480V 208V 480V 208V 480V 208V 480V
52RC AC Input
Contactor
60A 100A
52C AC Output
Contactor
60A 100A
52RS Bypass Contactor 60A 100A
72B Battery Disconnect
Contactor
80A 135A 200A
C
O
N
T
A
C
T
O
R
88RC Control circuit
Contactor
90A
FIU, FIV, FIW Inverter
Output Fuse
80A/660V 140A/660V
FOU, FOV, FOW Inverter
Output Fuse
80A/660V 140A/660V
FUA, FUB, FUC Control
Power Fuse
30A/600V
FSU, FSV, FSW
(Option)
Bypass
Input Fuse
140A/660V 280A/660V
FBP, FBN DC Input
Fuse
125A/1250V 200A/1250V 350A/1250V
FZS1, 2, 3 Bypass Input
ZNR Fuse
16A/500V
FBS1, 2 Control
Power Fuse
10A/600V
FUF1, 2 Control
Power Fuse
10A/600V
F
U
S
E
FZR1, 2, 3 AC Input
ZNR Fuse
16A/500V
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2.0 OPERATOR CONTROLS AND INDICATORS
The 2033D Series operator controls and indicators are located as follows:
Circuit breakers and contactors: Inside the module
UPS status indicators: Outside of front door
FIGURE 2.1 Operation/Display Panel (Front panel)
LOAD ON
INVERTER
BATTERY
OP.
LOAD ON
BYPASS
OVER LOAD
LCD
FAULT
UPS
FAULT
EMERG.STOP
1
2
6
3
5
4
9
8
MBP
540
V
52RC 52C
72B
STS
48A
7
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Mitsubishi 2033D SERIES User manual

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Brand
Mitsubishi
Model
2033D SERIES
Type
User manual
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